CN220335443U

CN220335443U - Handpiece for applying stitches to a decorative element having a three-dimensional conformation

Info

Publication number: CN220335443U
Application number: CN202320728468.7U
Authority: CN
Inventors: 爱德华·J·温策尔; 拉米兹·M·哈巴巴
Original assignee: Entanhua Products Co ltd
Current assignee: Entanhua Products Co ltd
Priority date: 2022-04-04
Filing date: 2023-04-04
Publication date: 2024-01-12
Anticipated expiration: 2033-04-04
Also published as: CN116892089A

Abstract

A handpiece for applying stitches to a decorative member having a three-dimensional configuration, comprising: a needle bar assembly operably coupled to the handpiece; a looper configured to cooperate with the needle bar assembly to form a plurality of stitches in the ornamental component, the looper rotating in a plane parallel to the ornamental component; and a strut assembly configured to drive the curved needle to reciprocate in a plane, wherein the strut assembly is operably coupled to a motor configured to drive the needle bar assembly in a reciprocating manner, the strut assembly being operably connected to the handpiece through the cylindrical arm assembly and the lower shaft assembly; wherein the cylindrical arm assembly is coupled to the swing frame drive shaft by a mechanical linkage and rotates in synchronization with the swing frame.

Description

Handpiece for applying stitches to a decorative element having a three-dimensional conformation

Technical Field

The present utility model relates to an interior structure for a vehicle interior. More particularly, the present utility model relates to an apparatus and method for stitching vehicle interior components. Still further, various embodiments of the present utility model relate to placing decorative stitching on a trim piece having a three-dimensional configuration, whether or not it is used in a vehicle.

Background

Most stitches found in automotive interiors are functional in that two or more pieces of material (leather, vinyl, TPO, cloth, etc.) are cut from a base, then sewn together (cut-n-sew)) and then wrapped around the seat cushion, headrest, armrest cover, instrument panel substrate, etc. Such functional stitching is very labor intensive and is typically used only where needed in low and medium range vehicles. Functional stitching on trim parts such as instrument panel fasteners and door panels is often limited to high-grade vehicles for cost reasons.

In recent years, automotive Original Equipment Manufacturers (OEMs) have shown interest in applying a "stitch" look to more vehicles with a wider range of price classes. Analog nonfunctional stitches are used in some applications, but there is currently no production feasibility of analog stitches that provide contrasting colors. In addition, more and more original equipment manufacturers have required the use of real or "lively" stitches on decorative parts to provide the look and feel of a truly tailor part.

Current methods of disposing decorative stitching on 3D preformed automotive trim parts include piercing the part (skin, skin/foam or skin/foam/substrate) with a needle from the top side of the part and engaging hooks or loopers located on the back of the part. These methods require access to the front and back surfaces of the part, which typically limits the location of the trace placement on the part. As is common in true tailor automotive interiors, it is often very difficult to provide stitches on ridges, sharp corners and highly contoured surfaces.

For example, stitching in a direction perpendicular to and across the edges of the semi-rigid component remains difficult because the needle board depth requirements on existing machines prevent the board from conforming to smaller radii. Furthermore, stitching around small in-plane radii can also be difficult because of the need to predefine gaps for movement of the needle board.

It is therefore desirable to provide a method and apparatus for producing vivid, nonfunctional stitches on decorative automotive trim parts. It is also desirable to provide a component with such stitching.

Disclosure of Invention

In one embodiment, an apparatus and method for applying stitching to a trim component having a three-dimensional configuration is provided.

In one embodiment, the apparatus has a handpiece to which a needle bar assembly is operatively coupled; a looper configured to cooperate with the needle bar assembly to form a plurality of stitches in the ornamental component, the looper rotating in a plane parallel to the ornamental component; a strut assembly configured to drive the curved needle in a reciprocating manner in a plane, wherein the strut assembly is operably coupled to a motor configured to drive the needle bar assembly in a reciprocating manner.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the needle bar assembly may be reciprocally driven by an upper drive shaft operatively coupled to the motor, and the strut assembly may also be reciprocally driven by the upper drive shaft through an intermediate drive shaft.

In addition to one or more features described above, or as an alternative to any of the foregoing embodiments, the strut assembly may be operably coupled to the handpiece by a cylindrical arm assembly and a lower shaft assembly.

In addition to one or more features described above, or as an alternative to any of the foregoing embodiments, at least one of the cylindrical arm assembly and/or the lower shaft assembly may be removably secured to the handpiece such that the other cylindrical arm assembly and/or the other lower shaft assembly can be secured to the handpiece such that the strut assembly is repositioned relative to the needle shaft assembly of the handpiece.

In addition to one or more features described above, or as an alternative to any of the foregoing embodiments, the cylindrical arm assembly and the lower shaft assembly may be interchanged with another cylindrical arm assembly and another lower shaft assembly such that the strut assembly may be repositioned relative to the needle shaft assembly.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, another needle and another curved needle may be provided that is configured to cooperate with the other needle to simultaneously provide two separate patterns of multiple stitches in the decorative component, the other curved needle rotating in a plane parallel to the decorative component.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the strut assembly may be configured to drive the curved needle and the other curved needle to reciprocate in a plane, wherein the strut assembly is operably coupled to a motor configured to drive the needle shaft assembly comprising the two needles in a reciprocating manner.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the loopers may be located in a pillar housing of the pillar assembly that is only slightly larger than the looper size such that a needle board of the pillar housing may be located near the back of the trim component.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the loopers may be located in a pillar housing of the pillar assembly that is only slightly larger than the looper size such that a needle board of the pillar housing may be located near a back side of the trim component and wherein the dimensional direction is aligned or coincident with a stitch direction of the plurality of stitches.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the dimension may be in the range of 10-12 mm.

In another embodiment, a hand piece for applying stitching to a decorative member having a three-dimensional configuration and angle is provided. The machine head comprises: a needle bar assembly operably coupled to the handpiece; a looper configured to cooperate with the needle bar assembly to form a plurality of stitches in the ornamental component, the looper rotating in a plane parallel to the ornamental component; and a needle bar assembly configured to drive the curved needle in a reciprocating manner in a plane, wherein the needle bar assembly is configured to drive the needle bar assembly in a reciprocating manner, the curved needle being located in a needle housing of the needle bar assembly, the needle housing being only slightly larger than the size of the curved needle such that a needle plate of the needle housing may be located near a back face of a corner of the trim component.

In addition to one or more of the features described above, or as an alternative to any of the preceding embodiments, the dimensional direction may be aligned with or coincident with the stitch direction of the plurality of stitches.

A decorative member may be provided having a plurality of stitches applied thereto by the nose of any of the foregoing embodiments, and the decorative member may be an interior trim piece of a vehicle.

A decorative member having a plurality of stitches applied thereto by the nose of any of the preceding embodiments, wherein the interior trim piece may be an instrument panel.

A decorative member having a plurality of stitches applied thereto by the handpiece of any of the foregoing embodiments, wherein at least some of the plurality of stitches may be applied at corners of the decorative member.

In another embodiment, a method of applying stitching to an interior component of a vehicle is provided, the interior component comprising at least one layer. The method comprises the following steps: a) Piercing the at least one layer with a needle at an entry point on a first surface of the at least one layer, wherein the piercing step causes the needle to reach a bottom dead center of its travel range and also causes a roof line to pass through the at least one layer at an exit point on a second surface opposite the first surface; b) Capturing the thread with a rotating curved needle positioned near the exit point, wherein the rotating curved needle rotates in a first direction in a plane parallel to the at least one layer; c) Retracting the needle through the exit point and the entry point to a top dead center position of its travel range; d) Advancing the component in a first direction; e) Rotating the rotating curved needle in a second direction in a plane parallel to the at least one layer, the second direction being opposite to the first direction; f) Piercing the at least one layer with a needle at another entry point on a first surface of the at least one layer, wherein the piercing step causes a top line to pass through the at least one layer at another exit point on a second surface opposite the first surface, and wherein the needle engages a bottom line located on a rotating curved needle; g) Loosening the top line when the rotating curved needle rotates in the second direction; h) Completing the stitch between the top and bottom threads when the rotating curved needle rotates in the second direction to the final position and the needle reaches the bottom of its downward stroke; and i) repeating steps b-h until a desired number of stitches are formed in the interior component.

In addition to one or more of the features described above, or as an alternative to any of the preceding embodiments, the skin layer may be formed from the group consisting of vinyl, leather, and thermoplastic polyolefin.

In addition to one or more features described above, or as an alternative to any of the foregoing embodiments, an interior component is formed by the method described above and may be an interior trim piece of a vehicle.

In addition to one or more of the features described above, or as an alternative to any of the preceding embodiments, the interior trim piece may be part of a vehicle dashboard.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the interior trim piece may be part of a vehicle dashboard.

In addition to one or more of the features described above, or as an alternative to any of the preceding embodiments, the skin layer may be formed from the group consisting of vinyl, leather, and thermoplastic polyolefin; and an intermediate layer may be applied on a second surface of the skin layer, the second surface being opposite the first surface.

In addition to one or more of the features described above, or as an alternative to any of the preceding embodiments, the intermediate layer may be a foam layer.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the interior component may be an interior trim piece of a vehicle.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the internal components may be formed by the methods described above.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the interior components of the vehicle may be formed by the methods described above.

Also provided herein is an interior component of a vehicle formed by the above method.

Disclosed is a handpiece for applying a stitch on a decorative member having a three-dimensional configuration, comprising: a needle bar assembly operably coupled to the handpiece; a looper configured to cooperate with the needle bar assembly to form a plurality of stitches in the ornamental component, the looper rotating in a plane parallel to the ornamental component; a strut assembly configured to drive the curved needle in a reciprocating manner in a plane, wherein the strut assembly is operably coupled to a motor configured to drive the needle bar assembly in a reciprocating manner, the strut assembly being operably coupled to the handpiece via the cylindrical arm assembly and the lower shaft assembly; wherein the cylindrical arm assembly is coupled to the swing frame drive shaft by a mechanical linkage and rotates in synchronization with the swing frame.

In addition to one or more of the features described above, or as an alternative to any of the preceding embodiments, the needle bar assembly is reciprocally driven by an upper drive shaft operatively connected to the motor, and the strut assembly is reciprocally driven by the upper drive shaft via an intermediate drive shaft.

In addition to one or more features described above, or as an alternative to any of the preceding embodiments, at least one of the cylindrical arm assembly and/or the lower shaft assembly is removably secured to the handpiece such that the other cylindrical arm assembly and/or the other lower shaft assembly can be secured to the handpiece such that the strut assembly is repositioned relative to the needle bar assembly of the handpiece.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the other needle and the other looper are configured such that the other looper cooperates with the other needle to simultaneously provide two separate patterns of multiple stitches in the decorative component, the other looper rotating in a plane parallel to the decorative component.

In addition to one or more features described above, or as an alternative to any of the foregoing embodiments, the strut assembly is configured to drive the curved needle and the other curved needle to reciprocate in a plane, wherein the strut assembly is operatively connected to a motor configured to drive a needle bar assembly comprising the two needles in a reciprocating manner.

In addition to one or more of the features described above, or as an alternative to any of the preceding embodiments, the topping wire stopper is configured to control the size and stabilize the position of the topping wire loop prior to and during engagement of the topping wire with the looper.

Drawings

Other features, advantages and details are presented in the following description of embodiments by way of example only, with reference to the accompanying drawings, in which:

FIG. 1A is a cross-sectional view of a swing chain sewing machine according to an exemplary embodiment of the present utility model;

FIG. 1B is a perspective view of an oscillating butterfly curved needle in accordance with a non-limiting embodiment of the utility model;

FIG. 2 is a cross-sectional view of a swing chain sewing machine having an adjustable lower assembly according to an exemplary embodiment of the present utility model;

FIG. 3A is a cross-sectional view of an oscillating looper drive unit according to an exemplary embodiment of the present utility model;

FIG. 3B is a cross-sectional view of the post and looper assembly combination;

FIG. 4 is a cross-sectional view of an oscillating looper design according to an exemplary embodiment of the present utility model;

FIG. 5 is a cross-sectional view of an oscillating looper design according to an alternative exemplary embodiment of the present utility model;

FIG. 6A is a diagram illustrating the formation of a stitch according to an embodiment of the present utility model;

FIG. 6B is a view taken along line 6B-6B in FIG. 6A;

FIG. 7A is a diagram illustrating the formation of a stitch according to an embodiment of the present utility model;

FIG. 7B is a view taken along line 7B-7B in FIG. 7A;

FIG. 8A is a diagram illustrating the formation of a stitch according to an embodiment of the present utility model;

FIG. 8B is a view taken along line 8B-8B in FIG. 8A;

FIG. 9A is a diagram illustrating the formation of a stitch according to an embodiment of the present utility model;

FIG. 9B is a view taken along line 9B-9B of FIG. 9A;

FIG. 10A is a diagram illustrating the formation of a stitch according to an embodiment of the present utility model;

FIG. 10B is a view taken along line 10B-10B of FIG. 10A;

FIG. 11A is a diagram illustrating the formation of a stitch according to an embodiment of the present utility model;

FIG. 11B is a view taken along line 11B-11B in FIG. 11A;

fig. 12A and 12B illustrate the needle plate footprint of various embodiments of the present utility model;

FIG. 13 shows a hook assembly at a corner of a part;

FIG. 14 illustrates an oscillating looper according to an exemplary embodiment of the present utility model;

FIG. 15 illustrates a method of adding a cylindrical arm or cylindrical arm assembly transporter at a handpiece;

FIGS. 16A-16C illustrate the orientation of the swing frame relative to the cylindrical arm at three points in the suture cycle;

17A-17E illustrate the use of a wire brake or brake pad to control the size and stabilize the position of the top wire loop prior to engagement with the looper;

FIGS. 18A-18D illustrate the use of a wire brake or brake pad to control the size and stabilize the position of the top wire loop prior to engagement with the looper; and

fig. 19 is a top view of looper 12 capturing a top wire loop.

Although the drawings depict different embodiments and features of the utility model, the drawings are not necessarily to scale and certain features may be exaggerated in order to illustrate and explain an exemplary embodiment of the present utility model. The exemplifications set out herein illustrate several aspects of the utility model, in one form, and such exemplifications are not to be construed as limiting the scope of the utility model in any manner.

Detailed Description

Various embodiments of the present utility model are directed to a method and apparatus that is capable of applying decorative stitching to a limited stitch area of a preformed component within the transportation industry, particularly when placing stitching on a small radius shaped edge or around a small in-plane radius. The apparatus is also capable of adjusting machine parameters to accommodate various part sizes without the need to construct multiple sewing heads.

In another embodiment, the utility model includes a suture method and handpiece design for use in the transportation industry that enhances the ability to suture in a limited area of a three-dimensional shaped part in a manual or automated manner.

Referring to fig. 1A-4, a swing chain sewing machine 10 is shown in accordance with a non-limiting embodiment of the present utility model. Machine 10 provides chain stitch by using an oscillating butterfly looper 12 at the end of a combined looper and strut assembly 14, the combined looper and strut assembly 14 being operatively coupled to a cylindrical arm assembly 16.

This particular concept provides an extremely narrow strut housing in the "x" direction (at least as shown in fig. 1B, 12A and 12B) coincident with the stitch direction. In one embodiment, the size of the strut housing may be in the range of 10-12mm (millimeters), although sizes greater or less than this are considered to be within the scope of the present utility model. In a two-needle design, the two strut housings may span a dimension in the range of 25-28mm, while the "x" direction shown may range from 10-12mm, although greater or lesser dimensions are considered to be within the scope of the utility model. The narrow leg housing extends from the cylindrical arm all the way to the top of the looper/needle plate and is smaller than all previously known designs in this application environment. In one embodiment, the swing chain sewing machine or head 10 may be used as a stationary machine and the material or product fed via one or more feed devices incorporated with the head or machine 10, or the head or machine 10 may be driven by an external drive (e.g., a 6-axis robot) schematically illustrated by frame 18 to move the sewing head 10 over and around the stationary components.

Handpiece or machine 10 includes a needle bar assembly 20, needle bar assembly 20 being driven by an upper drive shaft 22, upper drive shaft 22 being operatively coupled to a motor 24 for driving upper drive shaft 22. Intermediate shaft 26 is also operatively coupled to upper drive shaft 22 via a belt 28 or any equivalent means such that rotational movement of upper drive shaft 28 will also cause rotational movement of intermediate shaft 26. Intermediate shaft 26 is also operatively coupled to lower shaft assembly 30, and lower shaft assembly 30 is operatively connected to cylindrical arm assembly 16, which cylindrical arm assembly 16 is in turn operatively coupled to swing butterfly curved needle 12 via strut assembly 14.

Furthermore, the handpiece 10 may have an adjustable design such that it may be reconfigured to accommodate a variety of different part shapes and sizes by a reconfigurable lower arm assembly 32 (at least schematically shown in FIG. 2), the lower arm assembly 32 being composed of an adjustable lower shaft position, interchangeable cylindrical arm shaft and housing assemblies 16 having different lengths, and interchangeable lower shaft assemblies 30 having different lengths. As such and as shown in at least fig. 2, the vertical gap between the upper and lower portions of the handpiece (with or without extension of the cylindrical arm) may also be adjusted by using interchangeable lower shaft assemblies 30 and looper shaft/housing components (e.g., interchangeable cylindrical arm shaft and housing assemblies 16).

For example, the first lower shaft assembly 30 may be directly coupled to the intermediate shaft 26 in a housing 34 of an upper portion 36 of the machine or handpiece 10. A second lower shaft assembly 30' (shown in fig. 2) may then be operatively coupled to a lower portion of the first lower shaft assembly 30 to extend the length of the combined lower shaft assembly to position the oscillating curved needle 12 further from the needle bar assembly 20 of the handpiece 10.

In addition, the housing 34 and intermediate shaft 26 may also be configured to connect to a longer lower shaft assembly 30 "(also shown in phantom in FIG. 2). This allows the position of the lower shaft assembly 30 "to be moved in the direction of arrow 38, thereby allowing the lower shaft assembly 30" to be used with a cylindrical arm shaft and housing assembly 16' (also shown in phantom in FIG. 2). The length of the assembly 16' may be longer than the assembly 16 for use with the assembly 30 ". Thus, the interchangeable cylindrical arm shaft and housing assemblies 16, 16 'may be combined with the interchangeable lower shaft assemblies 30, 30', 30″ and interchangeable cylindrical components (e.g., looper shaft extensions and housings), as each assembly may be interchangeably connected to one another, thereby enabling a variety of configurations and sizes. Still further and as will be discussed herein, the dual post swing looper design may be used in combination with any of the disclosed components.

Thus, these embodiments allow the distance 40 between one end of needle bar assembly 20 and cylindrical arm 16 and the distance 41 between one end of needle bar assembly 20 and lower shaft assembly 30 to be varied, thereby allowing handpiece or machine 10 to accommodate various sized parts.

The description and illustrations mentioned above and below relate to a sewing machine head 10 that can operate in an automated manner over and around a stationary component, but is also applicable to stationary machines.

As described above, the structure of handpiece 10 includes upper shaft 22 driven by servo motor 24. The upper shaft 22 controls movement of the needle bar assembly 20 and the stepper foot located in the upper portion or head 10. The upper shaft 22 also drives the intermediate shaft 26 and the lower shaft 42 by a series of belts, pulleys, and gears that convert constant rotational motion to oscillating motion. A rocking motion is required to properly coordinate the motion of the looper 12 relative to the needle shaft assembly 20.

In one embodiment, the rocking motion includes rotation of the looper in both clockwise and counterclockwise motions, as well as acceleration and deceleration of the looper at different points in time during the motion. One possible non-limiting configuration for providing such movement and acceleration and deceleration is shown at least in fig. 3A. The intermediate shaft or drive shaft 26 has a cam 27, the cam 27 together with a cam fork 44 converting rotational motion into variable speed oscillatory motion, the cam fork 44 in turn driving an output shaft or lower shaft 42 through a series of linkages and gears denoted by reference numeral 45.

For example, gear and sector assembly 46 is connected to cam fork 44 by a link 47, causing oscillating movement of output shaft 42 and ultimately resulting in oscillating movement of a looper shaft 48 operatively coupled to looper 12. The angle of the gearing determines the rotational travel distance of the looper 12, which in one embodiment may be 220 degrees in one direction and then back again. Of course, degrees of rotation greater or less than 220 degrees are also understood to be within the scope of various embodiments of the present utility model. It will be appreciated that the manner in which the oscillating curved needle 12 is driven is not limited to the above description and may be reconfigured accordingly to achieve the same effect.

The looper leg assembly 14 may have a single looper 12 (see at least fig. 4), or the looper leg assembly may be configured with a double looper, hereinafter referred to as a double looper leg assembly 50 (see at least fig. 5), depending on the particular stitch configuration desired. As noted above, single or double curved needles may be used in any combination disclosed herein. In applications employing double curved needle strut assembly 50, handpiece 10 can also be configured to add a second needle to needle bar assembly 20 to provide a double trace pattern.

Referring again to fig. 4, the looper 12 is driven by the looper shaft 48 through a bevel gear 52, the bevel gear 52 meshing with a bevel gear 54 of the lower shaft 42. As shown in fig. 4, a bushing 56, collar lock 58, post housing 70, gear housing 72, and cylindrical arm assembly housing 74 are also provided to assist in transferring the oscillating rotational motion of lower shaft 42 to looper 12. As noted above, the configuration shown in the figures is merely one non-limiting exemplary embodiment for providing a rocking motion to curved needle 12, and various other means for providing a rocking motion are considered to be within the scope of the various embodiments of the present utility model.

As shown in fig. 5, a second looper 12, looper shaft 48, collar lock 58 and bevel gear 52, and bushing 56 are provided in an extended gear box 72 to drive a pair of loopers 12.

One non-limiting example of the sequence required to complete the stitch is described below and shown at least in fig. 6A-11A. In step 1 (fig. 6A), the curved needle 12 is in its fully counter-clockwise rotated position or at the beginning of its rotation and the needle 72 of the needle bar assembly 20 is at the bottom of its travel (bottom dead center BDC).

Fig. 6A-11A also illustrate at least the parts or portions 74 thereof to be stitched by handpiece 10, needle plate 76, and openings or holes 78 in needle plate 76 that allow access to needles 72. At least a portion of the needle plate 76 may be located about the housing 70 of the looper leg assembly 14. Also shown is a stepped presser foot 80 of needle bar assembly 20. The stepping foot 80 is operatively connected to the upper drive shaft 22 to provide the desired reciprocating motion of the stepping foot 80 as the needle 72 moves up and down between its top dead center position and its bottom dead center position. In fig. 6A, needle 72 is at the bottom or (bottom dead center) of its travel and curved needle 12 is at the beginning of its rotation. In addition, the stepping presser foot 80 is in contact with the material 74 but exerts little pressure thereon. Fig. 6B is a view taken along line 6B-6B in fig. 6A.

In step 2 (fig. 7A), needle 72 begins to move upward in the direction of arrow 82, forming a loop 84 in a top line 86 between the tip of needle 72 and the back of the previous piece 74. At the same time, the tip 88 of the looper 12 moves clockwise in the view shown in the figures between the wire loop 84 and the needle 72. In addition, the stepping presser foot 80 applies slight pressure to ensure that the material 74 remains in contact with the needle plate 76 as the needles 72 retract from the material 74. Fig. 7B is a view taken along line 7B-7B of fig. 7A.

In step 3 (fig. 8A), the needle 72 has been moved away from the feature 74 and positioned in its fully retracted (top dead center TDC) position. With respect to the view shown in the figures, the looper 12 has been moved to its fully clockwise rotated or maximum rotated position with the top wire loop 84 fully located on the arm 90 of the looper 12. The stepping presser foot 80 is also lifted off the part 74 and begins to advance to the next needle penetration point on the part 74. Fig. 8B is a view taken along line 8B-8B of fig. 8A.

In step 4 (fig. 9A), needle 72 has been moved downwardly in the direction of arrow 73 and penetrated part 74 again and engaged with curved needle 12. Needle 72 is now in a downward stroke and needle 72 moves between lower wire or bobbin thread 92 and looper 12 as looper 12 is rotated counterclockwise relative to the view shown in the figures. As the needle 72 enters the material, the stepped presser foot 80 moves downwardly in the direction of arrow 73 into light contact with the material or part 74. Fig. 9B is a view taken along line 9B-9B of fig. 9A.

In step 5 (fig. 10A), as the curved needle 12 continues its counterclockwise rotation relative to the view shown in the figure, the needle 72 continues to move downwardly in the direction of arrow 73 on its downward stroke, releasing the top wire ring 84. In step 5 of fig. 10A the looper 12 releases the top wire 86. Fig. 10B is a view taken along line 10B-10B of fig. 10A.

At step 6 (fig. 11A and 11B, where fig. 11B is a view taken along line 11B-11B of fig. 11A), needle 72 reaches the bottom of its travel (bottom dead center) and curved needle 12 is in an end position rotated counterclockwise relative to the illustrated view, top wire 84 is pulled against back surface 75 of material 74 as the stitch is completed, pulling bottom wire 92. Thus, as the sewing head 10 moves forward relative to the part 74, the top wire loop 84 is pulled upward, simultaneously pulling the bottom wire 92, thereby completing the stitch.

The oscillating looper design described herein requires a minimum needle plate depth to accommodate looper 12 (see at least fig. 12), which moves back and forth in a plane perpendicular to the part to form stitches when looper 12 rotates in a plane parallel to part 74 (see at least fig. 6A-11B), which is more common on chain stitch machines. The needle plate depth is determined by the minimum looper diameter required to handle the desired thread size. This compact design enables stitching of the planar radius on the molded part, which was not previously possible using more conventional equipment (see, e.g., fig. 13 and 14).

As shown in FIG. 13, the corner 96 of the piece 74 can be stitched by the handpiece 10 because the looper 12 can be positioned closer to the back of the corner 96 of the piece 74. This is due to the fact that there is little or no clearance between the needle plate 76 and the feature 74 or corner 96 to ensure a consistent uniform stitch appearance, especially at the corner 96. In contrast, as shown in FIG. 14, curved needle arm 98 rotates about axis 100 perpendicular to, rather than parallel to, the back of part 74 being sutured. As shown in fig. 14, there is an excessive gap between the needle plate 76 and the feature 74 or corner 96, and thus an irregular stitch length or skip near the corner 96 may be caused by the excessive gap. Accordingly, various embodiments of the present utility model allow for stitching at the narrow corners of the part 74. Thus, the part radius can now be determined by the visual appearance rather than the limitations of the machine/sewing process. In addition, by using the swing type looper 12, both the top and bottom threads are used to form the stitch.

The sewing machine support begins at one end of the cylindrical arm 16 and extends upwardly therefrom to terminate at the top of the needle plate 76. The size of the needle plate 76 and/or the struts or strut housing in the "x" direction shown in the drawings is limited only by the diameter of the looper 12 itself. No other mechanism in the pillar or pillar housing 70 at any point along the height of the pillar or pillar housing 70 increases its size, which allows the pillar or pillar housing 70 and its needle board 76 to be inserted into a narrow area, such as the corner 96 or any other difficult to reach narrow area with little clearance between the needle board 76 and the back of the part being stitched, resulting in a more efficient or effective stitch pattern.

It will also be appreciated that the lower shaft (output shaft) may be adjusted relative to the looper shaft to provide better access to the back of the part.

Referring to fig. 15, a method of incorporating a cylindrical arm or cylindrical arm assembly transporter into handpiece 10 is shown. A cylindrical arm or cylindrical arm assembly 16 transporter may be used to maintain the proper relationship between needle 72 and looper 12 during stitch formation. Cylindrical arm drive link 102 is connected to swing frame drive shaft 101 of handpiece 10, and cylindrical arm drive link 102 is in turn pivotally connected to cylindrical arm follower link 103. Cylindrical arm follower link 103 is pivotally connected to cylindrical arm rotary drive clip 104, which is connected to cylindrical drive assembly 16. This configuration enables cylindrical arm assembly 16 to rotate about lower shaft 42 as swing frame 105 rotates about swing frame drive shaft 101. Because the rotation of the swing frame 105 about the swing frame drive shaft 101 controls the needle position in the sewing direction, connecting the rotational movement of the cylindrical arm assembly 16 to the swing frame drive shaft 101 will ensure that the interface of the carry needle bar hour hand 72 with the looper 12 is always correct.

Fig. 16A-16C illustrate the orientation of the swing frame 105 relative to the cylindrical arm 16 at three points in the suture cycle.

17A-17E illustrate the use of a wire brake or pad 106 to control the size and stabilize the position of the top wire loop prior to engagement with looper 12. Fig. 17A shows the needle in a Top Dead Center (TDC) position with the thread brake 106 retracted so that the top thread 86 is free to move through the bore of the needle 72. Fig. 17B shows that at a point along the downward travel of the needle shaft 107, the thread brake 106 begins to move forward toward the needle shaft 107, the thread brake 106 exerting a resistance to the passage of the topping thread 86 before the thread enters the bore of the needle 72. Fig. 17C shows that the thread brake 106 applies full pressure to the thread 86 against the needle shaft 107, preventing the top thread 86 from passing through the aperture of the needle 72. As the needle shaft continues downwardly from this point, the ejector ring is initially stroked and remains in place until captured by the looper 12. Fig. 17D shows the needle 107 in a Bottom Dead Center (BDC) position. Fig. 17E shows the curved needle 12 engaged with the top wire loop at a point of upward travel of the needle shaft 107. Also at this point, the thread brake 106 typically begins to disengage from the needle shaft 107, allowing the topping thread 86 to again pass freely through the bore of the needle 72.

When the needle bar 107 is at TDC (see at least fig. 17A), the spring steel arm 108 is pressed by the roller assembly 109 (due to the shape of the spring steel arm). Spring steel arm 108 is secured to the wire brake and is configured to provide a biasing force in the direction of arrow 111.

As the needle bar 107 moves downward (and with it the spring steel arm 108), the immovable roller 109 eventually reaches a point on the spring steel arm 108 where no deflection occurs, at which point the brake pad or wire brake 106 applies pressure, limiting the pressing of the wire 86 against the needle bar 107. This occurs when the needle shaft 107 is at about 50% of its downward stroke length.

Brake pressure is applied (spring deactivated) until the needle travel reaches BDC and remains applied until approximately 25% of the upward travel is reached until brake release begins (spring activated begins).

The wire brake 106 is fully released and remains released (spring activated) at 50% of the upward stroke of the needle bar 107 to balance the upward motion of the needle bar to TDC.

The brake engagement and release points described above are approximations and can be adjusted by moving the position of the roller assembly 109 up or down, depending on the application and the wire used.

Of course, it will be appreciated that other ways of brake activation/deactivation are possible.

Fig. 18A-18D also illustrate the use of wire brake 106 to control the size and stabilize the position of the top wire loop prior to engagement with looper 12. Fig. 18A shows the needle in a Top Dead Center (TDC) position with the thread brake 106 retracted allowing the top thread 86 to move freely through the bore of the needle 72, while fig. 18B and 18C show a point along the downward movement of the needle 72 and needle shaft 107 where the thread brake 106 has been activated. Fig. 18D shows the needle bar 107 in a Bottom Dead Center (BDC) position with the line brake activated.

Fig. 19 is a top view of looper 12 capturing a top wire loop.

It should be appreciated that the position and timing of the engagement/disengagement of the wire brake 106 with the needle shaft 107 may be adjusted as needed to form an optimal top wire loop before and during capture of the looper 12.

In one embodiment, the part 74 may be part of a vehicle interior. In one embodiment, the portion may be any portion of the vehicle interior. For example, the portion may comprise a portion of a dashboard of the vehicle. Of course, the portion may be located on any surface within the vehicle. Non-limiting examples include door panels, vehicle armrest lids, vehicle armrest panels, dashboards, vehicle armrests, headliners, seat backs, packaging trays, any decorative vehicle interior surface. Still further, the methods disclosed herein may be applied to articles or components used in other non-vehicle manufacturing processes, and thus the portion or part 74 may refer to any article of manufacture.

The inner portion or article or part 74 may be of single or multi-layer construction. In one embodiment, the part 74 includes at least an outer skin layer having a substantially smooth outer surface and a back surface facing away from the outer surface. The skin layer is preferably formed of a plastic material having significant flexibility and aesthetic properties. Of course, other natural materials (e.g., leather, etc.) and artificial coverings are considered useful in various embodiments of the utility model. In one embodiment, the interior portion is a decorative element of a vehicle interior.

To enhance the softness of the interior, in one embodiment, a layer of cushioning support material may be provided in the area below the skin layer. It is contemplated that the cushioning support material may have any number of different configurations, although foam materials such as cross-linked polypropylene (XLPP) or Polyurethane (PU) foam may be potentially preferred.

A dimensionally stable substrate of plastic or other suitable material may also be provided under the cushioning support material.

According to one embodiment, the cushioning support material and the substrate may cooperate to provide a support structure for the skin layer.

It is contemplated that the PU foam forming the cushioning support material may be blow molded between the skin layer and the substrate to form a multi-layer composite structure. It is also contemplated that the cushioning material may be attached to the skin layer in a preliminary cladding operation to form a preliminary layered composite material, which may then be applied to any substrate as may be used. It is also contemplated that the cushioning material may be attached to the outer substrate layer in a preliminary cladding operation to form a preliminary layered composite, which may then be wrapped with an outer skin layer.

Further, the portion may be any one of a single layer (skin only), a double layer (skin/foam), or a three layer (skin/foam/substrate). In yet another alternative embodiment, the intermediate foam layer between the skin and the substrate may be a spacer fabric rather than a foam layer. In yet another alternative embodiment, the spacer fabric may be used in combination with a foam layer between the skin and the foam layer, or a foam layer between the substrate and the foam layer, or both between the skin and the foam layer and between the foam layer and the substrate. Accordingly, the methods and related apparatus disclosed herein are contemplated for use with any of the above-described configurations of part 74.

In another embodiment, the part 74 may be formed by a vacuum forming process or from a vacuum formed component that may have a single layer or multiple layers, some of which may be formed from different materials and wherein the component has a three-dimensional configuration of different configurations. Furthermore, the above-described parts may have rigidity that does not bend sufficiently during the suture process or application.

As noted above, it is desirable to provide vivid, nonfunctional stitches on decorative automotive trim parts without the use of expensive tailor technology. According to one embodiment of the utility model, the method is used to implement dual traces that are adjacent (e.g., opposite and parallel to each other).

Various embodiments of the present utility model relate to alternative methods of applying decorative stitching to the construction of unformed and preformed materials used in the transportation industry or in the manufacture of vehicles and vehicle components. The method disclosed herein can be used with two flat sheet materials (cut-and-stitch), but can provide greater benefits when applied to components that have a degree of rigidity that cannot be easily flattened without damaging the material.

The terms "first," "second," and the like, as used herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another, and the terms "a," "an," and the like do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. In addition, it should be noted that the terms "bottom" and "top" are used herein for convenience of description only and are not limited to any one position or spatial orientation unless otherwise specified.

The modifier "about" used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., includes the degree of error associated with measurement of the particular quantity).

While the utility model has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the utility model. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the utility model without departing from the essential scope thereof.

Claims

1. A handpiece for applying stitches to a decorative member having a three-dimensional configuration, comprising:

a needle bar assembly operably coupled to the handpiece;

a looper configured to cooperate with the needle bar assembly to provide a plurality of stitches in the decorative component, the looper rotating in a plane parallel to the decorative component; and

a strut assembly configured to drive the curved needle to reciprocate within the plane, wherein the strut assembly is operably coupled to a motor configured to drive the needle bar assembly in a reciprocating manner, the strut assembly being operably connected to the handpiece by a cylindrical arm assembly and a lower shaft assembly;

wherein the cylindrical arm assembly is connected to the swing frame drive shaft by a mechanical linkage and rotates in synchronization with the swing frame.

2. The handpiece of claim 1, wherein the needle bar assembly is reciprocally driven by an upper drive shaft operatively coupled to the motor, and the strut assembly is reciprocally driven by the upper drive shaft via an intermediate drive shaft.

3. The handpiece of claim 2, wherein at least one of the cylindrical arm assembly and/or the lower shaft assembly is detachably secured to the handpiece such that the other cylindrical arm assembly and/or the other lower shaft assembly is securable to the handpiece such that the strut assembly is repositioned relative to the needle bar assembly of the handpiece.

4. The handpiece of claim 1, wherein at least one of the cylindrical arm assembly and/or the lower shaft assembly is detachably secured to the handpiece such that the other cylindrical arm assembly and/or the other lower shaft assembly is securable to the handpiece such that the strut assembly is repositioned relative to the needle bar assembly of the handpiece.

5. The handpiece of claim 1, wherein the cylindrical arm assembly and the lower shaft assembly are interchangeable with another cylindrical arm assembly and another lower shaft assembly such that the strut assembly is repositionable relative to the needle shaft assembly.

6. The handpiece of claim 1, further comprising: a further needle and a further looper configured to cooperate with the further needle to simultaneously provide two separate patterns of a plurality of stitches in the decorative component, the further looper rotating in a plane parallel to the decorative component.

7. The handpiece of claim 6, wherein the strut assembly is configured to drive the curved needle and the other curved needle to reciprocate in the plane, wherein the strut assembly is operably coupled to a motor configured to drive the needle shaft assembly comprising two needles in a reciprocating manner.

8. The handpiece of claim 7, further comprising: a topping wire brake configured to control a size of the topping wire loop and stabilize the topping wire loop position before and during the topping wire is engaged with the looper.

9. The handpiece of claim 2, further comprising: a topping wire brake configured to control a size of the topping wire loop and stabilize the topping wire loop position before and during the topping wire is engaged with the looper.

10. The handpiece of claim 1, further comprising: a topping wire brake configured to control a size of the topping wire loop and stabilize the topping wire loop position before and during the topping wire is engaged with the looper.